Fuel Pump: Removal

HINT:

See PRECAUTION  .

1. Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.
   Fig 1: Identifying No. 2 Rear Floor Service Hole Cover

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1. Disconnect the connector from the fuel suction with pump and gauge assembly.
2. Disconnect fuel pump tube.
   NOTE: Before beginning this procedure, check for foreign matter on the joint clips. Clean if necessary.
   Fig 2: Locating Connector Of Fuel Suction With Pump And Gauge Assembly

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   1. Remove the 2 tube joint clips, fuel tank main tube and fuel tank return vent tube.
      NOTE:

      • Keep the O-ring free of foreign matter, as it becomes contaminated easily.
      • Do not use any tools in this procedure.
      • Do not forcefully bend or twist the tube.
      • Put the tube in a plastic bag to prevent damage and contamination.
      • If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect it.
      • Be careful not to damage any clips. If a clip is damaged, replace it.
        Fig 3: Removing Tube Joint Clips

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3. Remove the 8 bolts and the fuel tank vent tube set plate.

   HINT:

   While holding the fuel suction tube by hand, remove the fuel tank vent tube set plate.

   Fig 4: Locating Fuel Tank Vent Tube Set Plate Bolts

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4. Disconnect the fuel tube.
5. Remove the fuel suction tube from the fuel tank.

   HINT:

   • Make sure that the fuel sender gauge arm does not bend.
   • Do not damage the No. 2 fuel hose.
     Fig 5: Removing Fuel Suction Tube From Fuel Tank

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1. Disconnect the fuel sender gauge connector.
2. Press down on the sender gauge claw labeled A. Then slide the sender gauge upward.
   Fig 6: Pressing Down On Sender Gauge Claw Labeled A

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1. Using needle nozzle pliers, remove the E-ring.
   Fig 7: Identifying E-Ring

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2. Using a screwdriver with the tip taped, disengage the claw and remove the jet pump nozzle.
   Fig 8: Disengaging Claw And Remove Jet Pump Nozzle

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3. Using a screwdriver with the tip taped, disengage the 3 claws and remove the No. 1 sub-tank.
   Fig 9: Disengaging Claws And Remove No. 1 Sub-Tank

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4. Using a clip remover with the tip taped, remove the jet pump and No. 1 fuel sub-tank.
   NOTE: The O-ring is installed firmly between the jet pump and No. 1 fuel sub-tank. Therefore, the jet pump and No. 1 fuel sub-tank should be removed carefully using a clip remover.
   Fig 10: Removing Jet Pump And No. 1 Fuel Sub-Tank

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1. Disconnect the 2 connectors and terminal and remove the fuel pump wire.
   Fig 11: Locating Fuel Pump Connectors And Terminal

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2. Using a screwdriver with the tip taped, detach the 2 claws from the claw holes and remove the fuel pump.
   Fig 12: Detaching Claws From Claw Holes

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3. Remove the fuel pump seal from the fuel pump.
   NOTE: If the fuel pump seal still remains in the fuel filter, remove it using a wire tip (1 mm) that is formed as shown in the illustration. Be careful not to damage the sealing surface.
   Fig 13: Locating Fuel Pump Seal

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1. Using a screwdriver with the tip taped, disengage the 2 claws and remove the flange assembly.
   Fig 14: Disengaging Claws And Remove Flange Assembly

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1. Using a screwdriver with the tip taped, disengage the claw and remove the fuel relief valve assembly.
   Fig 15: Disengaging Claw And Remove Fuel Relief Valve Assembly

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1. Using a screwdriver with the tip taped, disengage the 2 claws and remove the jet pump.
   Fig 16: Disengaging Claws And Remove Jet Pump

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1. Remove the clip and fuel pressure regulator from the relief valve.
   Fig 17: Removing Clip And Fuel Pressure Regulator From Relief Valve

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2. Remove the 2 O-rings from the fuel pressure regulator.
   Fig 18: Identifying Fuel Pressure Regulator O-Rings

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